Analyzin CHAPTER | Malitcntnce Management PART ONE Survey of Maintenance Management Section I: Maintenance Organizations 1. Maintenance organizational chart ‘A. Current and complete - 4 pts B. Not complete or over 1 year old - 3 pts C. Not current and not complete - 2 pts D. None - 0 pts 2. Job descriptions are available for: ‘A. All maintenance positions (including supervisors) - 4 pts B. All maintenance positions (except supervisors) - 3 pts G. All maintenance supervisors (and no others) - 2 pts D. Less than 50% of all maintenance positions - 1 pt E. No job descriptions - 0 points 3. Maintenance supervisor to hourly maintenance employee ratio: A. 8:1 to 12:1 -4 pts B. 13:1 tol6:1 - 3 pts G. Less than 8:1 - 2 pts D. More than 16:1 - 1 pt E. No shitt maintenance supervisor - 0 pts 4, Maintenance planner to hourly maintenance employee ratio: 1 to 20:1 - 4 pts B. 10:1 to 14:1 - 3 pts C. 21:1 to 25:1 - 2 pts D. 26:1 to 30:1 - 1 pt B. No planner or any ratio other than those listed above - 0 pts2 Chapter 1 . Maintenance organizational assignments A. Responsibilities fully documented - 4 pts B, Responsibilities clear, good coverage, good dispatching - 3 pts ©. Informal supervision and coordination, some gaps in job coverage - 2 D. Maintenance reports to production/operation - 1 pt E. Unclear lines of authority, jurisdictional - 0 pts 6. Maintenance organization effort and attitude: A. Excellent, pride in workmanship at all levels - 4 pts B. Steady work rate, professional operation - 3 pts C. Average work pace, only a few complaints - 2 pts D. Only occasional good efforts, frequent job delays, many complaints - 1 E. Constant disagreements within maintenance organization and be- tween maintenance «ind operations/production/facilities - 0 pts 7. Maintenance shop/work arca locations: A. Perfect - 4 pts B. Good (some improvement possible) - 3 pts C. Pair (major improvement possible) - 2 pts D. Poor (major improvement required) +1 pt B. Unsuitable or nonexistent - 0 pts 8. Maintenance shop/vork area layouts A. Perfect - 4 pts B. Good (some improvement possible) - 3 pts ©. Pair (major improvement possible) - 2 pts D. Poor (major improvement required) - 1 pt B. Unsuitable or nonexistent - 0 pts 9. Maintenance tools/equipment quality and quantity: A. Perfect - 4 pts B. Good (some improvement possible) - 3 pts C. Pair (major improvement possible) - 2 pts D. Poor (major improvement required) - 1 pt B. Unsuitable or nonexistent - 0 pts 10. What percent of maintenance personnel are tied to a pay incentive plan based on output? A. All-4 pts B. 90% or more - 3 pts C. % or more - 2 pts D. 50% or more - 1 pt Less than 50% - 0 ptsAnalyzing Maintenance Management 3 Section 2: Training Programs in Maintenance 1 v 3 Supervisory training A. Allare trained when salaried and additional training is mandatory on a scheduled basis - 4 pts B. All are trained when salaried and additional training is offered on an optional basis - 3 pts &. The majority are trained when salaried - 2 pts D. The majority are offered and attend training, which is offered on an infrequent or irregular basis - 1 pt B, Few are given initial training and little or no additional training is provided - 0 pts Planner Training A. All planners/schedulers have been to one or more public seminars providing instruction on maintenance planning and scheduling - 4 B. All planners/schedulers are provided with a written training program for maintenance planning - 3 pts C. All planners/schedulers receive I-on-1 on-the-job training for at least 1 month - 2 pts D. Planner/scheduler training is on the job - 1 pt B. There is no planner/scheduler training program - 0 pts Details of planner training subjects (add 1 point for each of the subjects covered, and 0 points if there Is no planner (raining program) A. Work order planning and execution B. Material planning C. Scheduling practices D. Project planning General quality and productivity training A. Includes upper management, line supervision, hourly worker, support personnel - 4 pts B. Includes upper management, line supervision, hourly worke C. Includes upper management, line supervision - 2 pts D. Is for only upper management - 1 pt F. No training program - 0 pts 3pts Maintenance craft training A. Training is tied to « pay and progression program - 4 pts B. Formal job experience is required before employment and on-the- job training is provided - 3 pts. G. Formal job experience is required before hire - 2 pts D. Training is provided by on-the-job experien E. There are no formal training requirements for hire and no subse- quent training is provided ~ 0 pts4 Chapter 1 6. Maintenance training intervals. Formal maintenance training is provided t ALL maintenance craft employees at the frequency of: A. Less than 1 year - 4 pts B. Between 12 to 18 months - 3 pts C. Between 18 to 24 months - 2pts D. Not to all employees, but to some in any of the above frequencies - 1 E. No training is offered - 0 pts 7. Format of maintenance training A. Training is a mix of classroom and lab exereises- 4 pts B. Training is all classroom - 3 pts C. Training is all in lab or workshop environment - 2 pts D. Training is all on the job - 1 point E. No formal craft training program exists - 0 pts. 18 program instructors ing is done by outside contract expert - 4 pts 8, Training is done by staff subject expert - 3 pts C. Training is done by supervisors - 2 pts D. Training is done by hourly workers - 1 pt E. Training program does not exist - 0 pts 9. Quality and shill level of the maintenance work force A. Perfect - 4 pts B. Good (some improvement possible) - 3 pts C. Pair (major improvement possible) - 2 pts D. Poor (major improvement required) - 1 pt B. Unsuitable - 0 pts 10. Quality and skill level of the supervisory group A. Perfect - 4 pts B. Good (some improvement possible) - 3 pts G. Fair (major improvement possible) - 2 pts D. Poor (major improvement required) - 1 pt E. Unsuitable - 0 pts Section 3: Maintenance Work Orders 1. What percent of maintenance man-hours are reported to a work order? A. 100% - 4 pts B. 75% - 3 pts GC. 50% - 2 pts D. 25%-1 pt E. Less than 25% - 0 pts 2, What percent of maintenance materials are charged against a work order number when issued? A. 100% - 4 ptsAnalyzing Maintenance Management 5 4 cquipment/ 5. 75% - 3 pts 50% - 2 pts 25% - 1 pt E. Less than -O pts ercent of total jobs performed by maintenance are covered by 2 A. 100% - 4 pts B. 75% - 3 pts C. 50% - 2 pts -Ipt than 25% - 0 pts What percent of the work orders proc .ct number? ed in the system are tied to an ‘A. 100% - 4 pts B. -3 pts CG. 50% -2 pts D. -Ipt B. than 25% - 0 pts What percent of the work orders are opened under a priority that would be identilied as emergency or urgent? 6. A. Less than 20% - 4 pts B. 20 to 29% - 3 pts C. 30 to 39% - 2 pts D. Greater than 39% - 0 pts What percent of the work orders are available for historical data analy- sis? 7 for work qual 8. date requ A. 100% -4 pts What percent of the work orders are checked by a qualified individual and completeness? A. 100% - 4 pts B. 75% - 3 pts C. 50% -2 pts D. 25% - 1 pt E. Less than 25% - 0 pts What percent of the work orders are closed within eight weeks from the ted A. 100% - 4 pts B. 75% - 3 pts6 Chapter 1 E. Less than 25% - 0 pts 9. What percent of the work orders are generated from the preventive maintenance inspections? A. 80-100% - 4 pts B. 60-79% - 3 pts C. 40-59% - 2 pts D. 20-39% - 1 pt E. Less than 20% - 0 pts 10. Add 1 point for each of the categories you track by work orders? A. Required downtime B. Required craft hours G. Required materials D. Requestor's name Section }: Maintenance Planning and Scheduling 1. What percent of non-emergency work orders are completed within four weeks of the initial request? A. 90% or more - 4 pts B. 75 to 89% - 3 pts C. 60 to 74% - 2 pts D. 40 to 59%-1 pt B. Less than 40% - 0 pts 2. Work order planning (add 1 point for cach of the following covered) A. Craft required B, Materials required C. Tools required D. Specific job instructions or job plan 3. Percentage of planned work orders experiencing delays duc to poor or incomplete plans: A. Less than 10% - 4 pts B. 10 to 20% -3 pts G. 21 to 40% - 2 pts D. 41 to 50%-1 pt E. More than 50% - 0 pts 4, Who is responsible for planning the work orders? A. A dedicated maintenance planner - 4 pts B. A maintenance supervisor - 2 pts G. Each eraft technician - 0 pts D. Anyone else - 0 ptsAnalyzing Maintenance Management 7 5. Maintenance job schedules are issued: A. Weekly - 4 pts B. Biweeldy - 3 pts C. Between 3 and 6 days - 2 pts D. Daily =1 pt B. Any other frequ ey - O pts 6. The maintenance and production/facilities scheduling meeting is held: A. Weekly - 4 pts B. Biweekly - 3 pts G. Between 3 and 6 da D. Daily - 1 pt E. Any other frequeney - 0 pts 2 pts 7. The backlog of maintenance work is available by (add 1 point for each category). A. Graft required B. Department C. Requestor D. Date needed by requesting 8. When the job is completed, the actual time, material, downtime, und other information is reported by: A. The craftsmen performing the work - 4 pts B. The supervisor of the group - 3 pts C. Anyone else - 2 pts D. Information is not recorded - 0 pts 9, What percent of the time are actual measures compared to the estimates for monitoring planning effectiveness? A. 90% or more - 4 pts B. 75 to 89% - 3 pts C. 60 to 74% - 2 pts D, 40 to 59%- 1 pt B. Less than 40% - 0 pts 10. What is the reporting relationship hetween planners and supervisors? A. Both report to the same maintenance manager - 4 pts B. The planner reports to the supervisor - 2 pts G. The supervisor reports to the planner - 2 pts D. The supervisor and planner report to operations/facilities- 0 pts8 Chapter 1 Section 5: Preventive Maintenance 1. The preventive maintenance program includes: (add 1 point for each type included) A. Lubrication checklists B. Detailed inspection checklists G. Personnel specifically assigned to the PM program D. Predictive maintenance diagnosties such as vibration analysis, oil sample analysis, and infrared heat monitors 2. What percent of the PM inspection/task checklists are checked to insure completeness: A. 90% or more - 4 pts B. 75 t0 89% - 3 pts C, 60 to 74% - 2 pts D, 40 to 59%- 1 pt E. Less than 40% - 0 pts 3. What percent of the plant's critical equipment is covered by a preventive naintenance program? A. 90% or more - 4 pts, B. 75 to 89% -3 pts C. 60 to 74% - 2 pts D. 40 to 59% - I pt E. Less than 40% - 0 pts. 4. What percent of the PM program is checked against an equipment item's history annually to insure good coverage? A. 90% or more - 4 pts B. 75 co 89% -3 pi C. 60 to 74% - 2 pts D. 40 to 59%- 1 pt E. Less than 40% - 0 pts What percent of the PMs are completed within 1 week of the due date? A. 90% or more - 4 pts B. 75 to 89% - 3 pts G. 60 to 74% - 2 pts D. 40 to 59% - 1 pt E. Less than 40% - 0 pts 6. What determines the frequeney of a PM inspection or task/service in- terval? A. Program is condition-based - 4 pts B. Program is based on a combination of equipment run time and fixed calendar interval- 3 pts C, Program is based on equipment run time only - 2 pts D, Program is based on calendar intervals - 1 pt B. Program is dynamic and is scheduled based on completion date of previous task - 0 ptsAnalyzing Maintenance Management 9 7. What percent of the inspections/tasks include safety information, de- tailed inspection instructions, material requirements, and labor esti- mates? A. 90% or more - 4 pts 5 to 89% - 3 pts G. 60 to 74% - 2 pts D. 40 to- 59% - 1 pt E. Less than 40% - 0 pts 8. What percent of the corrective action work orders are generated from the PM inspection program? ‘A. 90% or more - 4 pts B. 75 to 89% - 3 pts C. 60 to 74% - 2 pts D. 40 to 59%-1 pt E. Less than 40% - 0 pts 9. PM actuals and results are checked annually for time and material esti- mate accuracy on what percent of the program? A. 90% or more - 4 pts B. 75 to 89% - 3 pts C. 60 to 74% - 2 pts D. 40 to 59%- 1 pt B. Less than 40% - 0 pts 10. Who is responsible for performing preventive maintenance tasks? A. Dedicated preventive maintenance personnel - 4 pts B. Specific individuals on cach crew - 3 pts ©. Any individual on a erew - 2 pts D. Entry level technicians - 1 pt E. Operating personnel - 0 pts Section 6: Maintenance Inventory and Purchasing 1, What percent of the time are materials in stores when required by the maintenance organization? A. More than 95% - 4 pts B. 80 to 95% - 3 pts CG. 70 to 79% - 2 pts D. 50 t0 69% - 1 pt E. Less than 50% - 0 pts 2. What percent of the items in inventory appear in the maintenance catalog? 90% or more - 4 pts 75 to 89% - 3 pts 2. 60 to 74% - 2 pts D. 40 to 59% - 1 pt E. Less than 40% - 0 pts10 Chapter 1 3. Who controls what are stocked as maintenance Inventory items? A. Maintenance - 4 pts B. Anyone else - 0 pts 4. The maintenance stores catalog is produced by: A. Alphabetic and numeric listings - 4 pts B. Alphabetic only - 2 pts C. Numeric only - 2 pts D. Catalog is incomplete or non-existent - 0 pts 5. The aisle/bin location is specified for what percent of the stores items? ‘A. More than 95% - 4 pts B. 90 to 95% - 3 pts C. 80 to 89% - 2 pts D. 70 to 79% - 1 pt E. Less than 70% - 0 pts 6. What percent of the maintenance stores items are issued to a work order or account number upon leaving the store? ‘A. More than 95% - 4 pts B. 90 to 95% - 3 pts C. 80 to 89% - 2 pts D. 70 to 79% - 1 pt E. Less than 70% - 0 pts 7. Maximum and minimum levels for the maintenance stores items are specified for what percent of the inventory? ‘A. More than 95% - 4 pts B, 90 to 95% - 3 pts ©. $0 to 89% - 2 pts D, 70 to 79% - 1 pt E. Less than 70% - 0 pts 8, What percent of the critical maintenance material is stocked in the ware- house or in a location readily accessible when the material is required? A. More than 95% - 4 pts B. 90 to 95% - 3 pts C. 80 to 89% - 2 pts D. 70 tw 79%- 1 pt B. Less than 70% - 0 pts 9. Maintenance stores inventory levels are updated daily upon receipt of materials what percent of the time? A. More than 95% - 4 pts B. 90 to 95% - 3 pts C. 80 to 89% - 2 pts D. 70 to 79% - 1 pt B. Less than 70% - 0 ptsAnalyzing Maintenance Management 1 10. What percent of the items are checked for at least one issue every months? A. 90% or more - 4 pts B. 80 to 89% - 3 pts C. 70 to 79% - 2 pts D. 50 to 69% - 1 pt E. Less than 50% - 0 pts Section 7: Maintenance Automation 1. What percentage of all maintenance operations utilize a CMMS? A. 90% or more - 4 pts B. 75 to 89% - 3 pts C. 60 to 74%- 2 pts D. 40 to 59% - 1 pt E. Less than 40% - 0 pts 2. What percentage of maintenance activities are planned and scheduled through a CMMS? A. 90% or more - 4 pts B. 75 to 89% - 3 pts ©. 60 to 74% - 2 pts D. 40 to 59% - 1 pt E. Less than 40% - 0 pts 3. What percentage of the maintenance inventory and purchasing fune- tions are performed in the system? A, 90% or more - 4 pts B. 75 to 89% - 3 pts C. 60 to 74% - 2 pts D. 40 to 59%- 1 pt E. Less than 40% - 0 pts. 4. Are the CMMS and the production scheduling system ‘A. Integrated - 4 pts B. Interfaced - 3 pt G. No connection ~ pts, 5. Are the CMMS and the payroll/ timekeeping system: ‘A. Integrated - 4 pts B. Interfaced - 3 pts ©. No connection — 0 pts 6, Are the CMMS and the financial/accounting A. Integrated - 4 pts B, Interlaced - 3 pts G. No connection — 0 pts12 Chapter 1 7. What percent of the maintenance personnel are using the system for their job functions with a high level of proficiency? ‘A. 90% or more - 4 pts B. 75 to 89% - 3 pts ©, 60 to 74% - 2 pts D. 40 to 59% - 1 pt E. Less than 40% - 0 pts 8. CMMS data is structured and maintained to facilitate reporting: A. 90% or more - 4 pts B. 75 to 89% - 3 pts C. 60 to 74% - 2 pts D. 40 to 59%- 1 pt E. Less than 40% - 0 pts. 9. CMMS data is utilized, on a regular bas ment decisions: A. Yes -4 pts B. Sometimes - 2 pts C. No- 0 pts 0 make cost effective manage- 10. CMMS data is used to verify progre A. Yes 4p B. No-0 pts Section 8: Operations/Facilities Involvement 1, What percent of operations personnel generate work order requests? A. 90% or more - 4 pts B. 75 to 89% -3 pts C. 60 to 74% - 2 pts D. 40 to 59%- 1 pt E. Less than 40% - 0 pts What percent of facilities personnel generate work order requests? A. 90% or more - 4 pts B. 75 to 89% - 3 pts C. 60 to 74% - 2 pts D. 40 to 59% - 1 pt B. Less than 40% - 0 pts 3. Operations work order priority is set for maintenance: A. Weekly in a joint operations/maintenance meeting - 4 pts B. Daily in a joint operations/maintenance meeting - 2 pts G. Itis set by maintenance with minimal operations input - 1 pt D. Itis random and based on emergency needs - 0 ptsAnalyzing Maintenance Management 13 4. Facility work order priority is set for maintenance: A. Weekly in a joint facility/maintenance meeting - 4 pts B. Daily in a joint facility/maintenanee meeting - 2 pts G. Itis set by maintenance with minimal facilities input - 1 pt D. Itis random and based on emergency needs - 0 pts 5. Operations/Operators are responsible and involved in the upkeep and performance of assets? A. Yes -4 pts B. No-0 pts 6, Add 1 point for eweh ta ined and certified to per- form: A. Inspections - B. Lubrication - GC. Minor maintenance task ~ D. Assist in maintenance repair work - ic that operators are tr 7. What percent of the time do operators follow-up and sign-off on com- pleted work orders? A. 90% or more - 4 pts B. 75 to 89% - 3 pts C. 60 to 74% - 2 pts D. 40 to 59%- 1 pt B. Less than 40% - 0 pts 8. What percent of the time do facilities personnel follow-up and sign-off on completed work orders A. 90% or more- 4 pts B. 75 to 89% -3 pts C, 60 to 74% - 2 pts D, 40 to 59% - 1 pt E. Less than 40% - 0 pts 9. laintenance is included in production/process scheduling meetings? A. All of the time - 4 pts B. Most of the time - 3 pts C. Oceasionally - 2 pts D. Seldom - 1 pt E. Never - 0 pts 10, Asset focused communication exists among maintenance, operations, engineering, and facilities personnel ‘A. Allof the time - 4 pts B. Most of the time - 3 pts C. Occasionally - 2 pts D. Seldom - 1 pt E, Never - 0 pts14 Chapter 1 Section 9: Maintenance Reporting 1. What percent of the time are the maintenance reports distributed on a timely basis to the appropriate personnel? A. 90% or more - 4 pts B. 75 to 89% - 3 pts C. 60 to 74% - 2 pts D. 40 t0 59%- I pt EB. Less than 40% - 0 pts 2. What percent of the time are the reports distributed within one day of the end of the time period specified in the report? ‘A. 90% or more - 4 pts B. 75 to 89% -3 pts C. 60 to 74% - 2 pts D, 40 to 59% - 1 pt E. Less than 40% - 0 pts 3. Add one point for each of the following equipment reports you produce: A. Equipment downtime in order of highest to lowest total hours (weekly or monthly) B. Equipment downtime in order of highest to lowest in total lost pro- duction dollars (weekly or monthly) G. Maintenance cost for equipment in order of highest to lowest (weekly or monthly) D. MTTR and MTBF for equipment 4, Add one point for each of the following preventive maintenance reports you produc ‘A. PM overdue report in order of oldest to most recent B. PM cost per equipment item in descending order ©. PM hours verses total maintenance hours per item expressed as a percentage D. PM costs verses total maintenance cos ed as a percentage per equipment item expres 5. Add one point for each of the personnel reports you produce: ‘A. Time report showing hours worked by employee divided by work order B. ‘Time report showing hours worked by craft in cach departmentarea G. Time report showing total hours spent by craft on emergeney/pre ventive/normal work D. Time report showing total overtime hours compared to regular hoursAnalyzing Maintenance Management. 15 6, Add one point for each of the planning reports you produce: A. Total work order costs estimated versus total work order actual costs by individual work order, by supervisor, or by crait B. A backlog report showing the total hours ready to schedule versus the craft capacity per week A planning efficiency report showing the hours and materials planned versus the actual hours and materials used per work order D. A planning effectiveness report showing the number of jobs closed out that were 20% over or under the labor or material estimates by planner and supervisor 7. Add one point for each of the scheduling reports you produce: A. Hours worked as scheduled compared to actual hours worked B. Weekly crew or crait capacity averaged for the last 20 weeks G. Total number of maintenance work orders scheduled compared to the aetual number of work orders completed D. Number of work orders spent on preventive maintenance compared to emergency maintenance and normal maintenance 8, Add one point for each of the inventory reports you produce: ‘A. Stock catalog by alphabetical and numerical listing B. Inventory valuation report ©. Inventory performance report showing stockouts and level of s turnover rate, ete. D. Inventory where used report vice, 9, Add one point for each of the purchasing reports you produce: ‘A. Vendor performance showing promised and actual delivery dates B. Price performance, showing the quoted and actual prices . Buyer or purchasing agent periormance report D. Non-stock report showing all direct buys for items not carried in stock for a specified period 10. Add one point for cach administrative roport you produce: A. Monthly maintenance costs versus monthly maintenance budget with a year-to-date total 8. Comparison of labor and material costs as a percentage of total maintenance costs G. Total costs of outside contractor usage broken down by contractor! project D. Maintenance cost per unit of production (or by square foot for facilities Section 10 Predictive Maintenance 1, The predictive maintenance program includes vibration analysis for: A. Critical/Non-critieal assets - 4 pts B. Critical only - 2 pts G. None - 0 pts16 Chapter 1 2. The predictive maintenance program includes thermography for: A. Critical/Non-critical assets - 4 pts B. Critical only - 2 pts C. None - 0 pts 3. The predictive maintenance program includes oil analysis for: A. Critical/Non-critical assets - 4 pts B. Critical only - 2 pts C. None - 0 pts 4. The predictive maintenance program utilizes sonics/whistle techniques for: A. Critical/Non-eritical assets - 4 pts B. Gritical only - 2 pts C. None - 0 pts 5. Condition-based monitoring is included in the predictive maintenan program. A. Yes-4 pts B. No-0 pts 6. Is the predictive maintenance system tied into the CMMS? ‘A. Integrated — 4 pts B. Interlaced ~ 3 pts C. Not electronically connected - 0 pts 7. Is the predictive maintenance data used to generate preventive corrective maintenance work orders? A. Yes - 4 pts B. No- Opts 8. Personnel are exclusively assigned to the predictive maintenance pro- gram. A. Yes- 4 pts B. No-0 pts 9. Predictive work is included as part of the weekly work schedule A. Yes-4 pts B. No-0 pts 10. Is predictive maintenance data used to improve asset performance and ney? B. No-0 pts Section II: Reliabil 1. The organization has a reliability engineering attitude/mentality. A. Yes, it exists as part of the work culture - 4 ptsAnalyzing Maintenance Management 17 2. B. Yes, it exists and is being developed as part of the work culture ©. No- 0 pts Complete and accurate asset data is available for Reliability Centered Maintenance analysis on: A. 90% or more of the assets - 4 pts B. 75 to 89% of the assets — 3 pts G. 60 to 74% of the assets ~ 2 pts D. 40 to 59% of the assets — 1 pt E. Less than 40% of the assets - 0 pts 3. Is the RCM methodology used to adjust/refine the PM/PDM program? A. Yes - 4 pts B. No-0 pts 4, RCM analysis is conducted on all assets: A. Annually - 4 pts B. Every 6 months - 3 pts G. Every 2 years - 2 pts D. Every 3 years - 1 pt E. Any longer than three years- 0 pts 5. The work order history is accurate in tracking the causes of failures: A. 90% or more of the asset's history - 4 pts B. 75 to 80% of the asset's history - 3 pts C. 60 to 74% of the asset's history - 2 pts D. 40 to 59% of the asset’s history - 1 pt B. Less than 40% of the asset's history - 0 pts 6. Are failures clearly identified? A. 90% or more of the asset's history - 4 pts B. 75 to 89% of the asset's history - 3 pts G. 60 to 74% of the asset’s history - 2 pts D. 40 to 59% of the asset's history - 1 pt B. Less than 40% of the asset's history - 0 pts 7. Failure analysis is conducted using analysis tool such as why tree, fish- bone, and Pareto, to assure accuracy and consistency of the effort. A. Yes - 4 pts B. No-0 pts 8, Dedicated personnel are permanently assigned to maintain the RCM program. A. Yes - 4 pts B. No-0 pts 9. Management views RCM as a value added activity A. Yes- 4 pts B. No-0 pts18 Chapter 1 10. Are methods in place for measuring the effectiveness of the reliability cengincering effort? ‘A. Yes 4 pts B. No-0 pts Section 12: Maintenance - General Practices 1, Is the total organization focused on asset utilization/optimization? A. Yes - 4 pts B. No-0 pts 2. The maintaining function is perceived as value added by (add 1 point for cach area) A. Management B. Operation C. Maintenan D. Stores and purchasing 3. The maintenance data collection system is utilized by (add 1 point for cach area): ‘A. Management B. Operations C. Maintenance D. Stores and purchasing 4. Operators are used for first line maintenance functions: A. Inall areas - 4 pts B. In some areas - 3 pts C, Ima few areas - 2 pts D, Not used at all - 0 pts 5. Overall equipment availability is calculated on key assets, processes, and lacilities: ‘A. 90% or more - 4 pts B. 60 to 89% - 3 pts ©. 30 to 39% - 2 pts D._Less than 30% - 0 pts 6. Operational decisions are made taking into account equipment reliability/availability. ‘A. 90% or more of the time - 4 pts B. 60 to 89% of the time - 3 pts 3. 30 to 59% of the time - 2 pts D. Less than 30% of the time - 0 pts 7. The right soft skills training classes (¢.g., communications, leadership) have been conducted for appropriate personnelAnalyzing Maintenance Management 19 A. 90% or more of the personnel - 4 pts B. 60 to 89% of the personnel - 3 pts C. 30 to 59% of the personnel - 2 pts D. Less than 30% of the personnel - 0 pts 8. ‘The right technical training classes have been conducted for appropri- ate personnel: A. 90% or more of the personnel - 4 pts B. 60 to 89% of the personnel - 3 pts C. 30 to 39% of the personnel - 2 pts D. Less than 30% of the personnel - 0 pts 9. Does the maintenance program comply with regulatory requirements and programs? A. Yes -4 pts B. No-0 pts 10. Are the financial effects of equipment availability/reliability under- stood and communicated to everyone? A. Yes -4 pts B. No-0 pts Section 13: Financial Optimization 1. Downtime duration is consistently tracked: A. Foralla —4 pts B. For key - 2 pts G. Not tracked at all - 0 pts 2. Downtime cost is clearly idem ties: A. For all areas ~ 4 pts B. For key areas only - 2 pts G. Not tracked at all - 0 pts 3. Downtime causes are accurately and consistently tracked: A. For all ai -4pt B. For key assets only - 2 pts Not tracked at all = 0 pts intcnance costs are clearly and accurately tracked: ‘A. For all assets — 4 pts B. For key assets only - 2 pts G. Not tracked at all - 0 pts 5. Other contributing cost for analysis: s (c.g, energy, quality, contractors) are available20 Chapter 1 A. All the costs ~ 4 pts B. Some of the costs - 2 pts C. None of the costs - 0 pts 6. Total operational costs are compared when making decisions: A. All cost factors - 4 pts B. Some cost factors- 2 pts C. No cost factors - 0 pts 7. Efficiency loss cost are available and accurate for: A, 90% or more of the assets - 4 pts B. 60 co 89% of the assets - 3 pts C. 40 to 59% of the assets - 2 pts D. 30 to 39% of the assets - 1 pt E. Less than 30% of the assets - 0 pts 8. A dedicated individual or team is assigned to analyze financial costs: A. Yes - 4 pts B. No-0 pts 9, Stores and purchasing costs are accurately tracked A. Yes - 4 pts B. No-0 pts 10. How available is financial information? ‘A. Available on demand - 4 pts B. Available daily - 3 pts G. Available weekly - 2 pts D. Available monthly - 1 pt B ilable - 0 pts Section 14: Asset Care Continuous Improvement 1. Is there visible management support for continuous improvement ef- forts? A. Strong support - 4 pts B. Moderate support — 3 pts CG. Weak support - 2 pts D. None - 0 pts Does the organization support continuous improvement efforts? A. Strong support - 4 pts B. Moderate support - 3 pts C. Weak support - 2 pts D. None - 0 pts 3. If the company has recently downsized, how has downsizing affected the organization?Analyzing Maintenance Management 2 A. Positive effect - 4 pts B. No effect - 2 pts C. Adverse effect - 0 pts 4, Past support of improvement efforts: A. Excellent - 4 pts B. Good - 2 pts C. Poor - 0 pts 5. The spirit of cooper A. Excellent - 4 pts B. Good - 2 pts C. Poor - 0 pts ation between plant management and labor is: 6. The following are focused on continuous improvement (add one point for each of the areas covered): A. Management B. Maintenance G. StoresPurchasing D. All other personnel 7. Management supports ongoing training designed to enhance employee skills: “A. Yes - 4 pts B. No-0 pts 8. Do continuous improvement efforts focus on ROI? A. Yes - 4 pis B. No-0 pts 9. Are continuous improvement efforts tied to reliability engineering? A. Yes -4 pts B. No-0 pts 10, Competitive forces influence continuous improvement efforts: A. 90% or more of the time - 4 pts B. 60 to 89% of the time - 3 pts C. 40 to 59% of the time - 2 pts D. 30 to 39% of the time - 1 pt B. Less than 30% of the time - 0 pts Section I Maintenance Contracting 1. The contract request process includes (add 1 point for each element included) ‘A. A formal process for requesting contract work B. Ancstablished approval process based on dollar value C. A mechanism to control what is and is not contracted22 Chapter 1 D. An automated request process 2, The responsibility for the contracting of work A. Is handled by a contracts specialist function solely focused on. contracts - 4 pts B. Is handled by a contracting function, but not solely focused on contracting - 3 pts Is handled by many job functions who have contracting responsibility - 2 pis D. Is handled by whoever needs contract work - 0 pts) 3. The approved list of contractors includes (add 1 point for each element included): A. A primary contractor for all required services B. An alternate in the event the primary is unavailable C. Validated requirements such as insurance and crafts rates D. Phone numbers for all contacts 4. The owner provides the following level of supervision for contracted field execution: A. Dedicated company personnel to admi ficld - 4 pts B, Company personnel who administer the contracts, although it is not their primary function - 2 pts G. No organizational structure to administer field execution - 0 pts strate the contract in the 5, Contraetor safety A. A joint effort (joint accountability) between the site and the contrae- tors - 4 pts B. Ilighly important, and the contractors are held accountable 3 pts Equaily important with the execution of the work - 1 pt D. Not as important as work execution - 0 pts 6. The computer system exists with the following contracting functionality on the front end of the process (add 1 point for each functionality): A. Contraet requisition B. Contract administration C. Contract approval processing D. Administration of contracts in the field - releasing of work 7, The computer system e: 's with the following contracting functionality on the back end of the process (add 1 point for each functionality) A. Contract employees linked to contract, rates, skills, certifications, ete B. Blectronic time sheets - paperless system C. Gate security electronically linked D. Invoice payment processesAnalyzing Maintenance Management 23 8. The contracting system is: A. Integrated with the site’s CMMS - 4 pts B. A fully functional system with interfaces to the site CMMS - 3 pts 2. A stand-alone system - 2 pts D. There is no system - 0 pts 9. The relationship between the site personnel and the site contractors A. A partnership focused on efficient and effective work execution - 4 pts B. A supportive superior/subordinate relationship - 3 pts G. Contractors are accepted, but not part of the team effort - 2 pts D. Adversarial; they are a necessary evil - 0 pts 10. The invoicing/eost tracking process is A. Ilighly developed so that those responsible know the costs daily - 4 B. Moderately developed; costs are available weekly - 3 pts C. The costs are only known when invoices (long lead time) - 2 pts D. Costs are not readily available to those controlling the work Opts Section 16: Document Management 1. The site's document management system is: A. Electronic and fully integrated with other systems ~ 4 pts B. Electronic and interfaced with other systems - 3 pts C. Electronic but stand alone - 2 pts D. Paper; non-clectronie — 0 pts wv ‘The number of drawings included in the A, 80% to 100% - 4 pts B. 50% to 79% - 3 pts C. 30% to 49% - 1 pt D. less than 30% - 0 pts 3. The site’s timing for migration to a fully functional and utilized docu- ment management system A. 1to 3 years —4 pts B. 3 to 5 years —3 pts C. Sor more years — 1 pt D. No plan - 0 pts 4, Document control procedures and associated work process: A. Exist for the system — 4 pts B. Are under development ~ 2 pts C. Do not exist - 0 pes24 Chapter 1 The personnel at the site: A. Have received training, fully understand and use the document management procedures ~ 4 pts B. Are in the process of being trained to use the procedures C. Do not follow the procedures or they do not exist - 0 pts D. Add 1 point if procedure refresher training is provided periodically 3 pts 6. The system has detailed indexing and search capabilities that: A. Make documents simple and easy to find — 4 pts B. Make documents difficult to find - 2 pts G. Indexing and search capability do not exist - 0 pts 7. The level of accessibility for users A. Users have access and it is easy to obtain information ~ 4 pts sers have access, but it is hard to find information 3 pts C. Users must go to a separate group that provides the information - 1 D. Information is not accessible for most users - 0 pts 8. The quality and level of document version control cellent — 4 pts B. Good ~3 pts GC. Average - 2 pts D, Poor=1 pt E. Very Poor ~ 0 pts 9. The number of documents included in the document management sys tem is: A. 80% to 100% - 4 pts B. 50% to 79% - 3 pts C. 30% to 49%- 1 pt than 30% - 0 pts 10. The document management system is used by: A. All maintenance personnel — 4 pts B. Managers and supervisors only ~ 2 pts C. Only staff personnel reporting to maintenance — 0 ptsAnalyzing Maintenance Management 25 PART TWO The Results In completing the survey above, an organization should develop insight into the effectiveness of its maintenanee/asset management function. The best score possible for this survey is 640 points. Over the past several years, more than 100 companies have participated in the survey, using it to measure themselves against the established criteria, Their average results are listed below on a section-by-seetion basis, By comparing your results to those listed below, you can identify maintenance process areas that need improvement. ons tenance 1. Maintenance Organi: 2. Training Programs in Ma 3. Maintenance Work Orders 4, Maintenance Planning and Scheduling 5. Preventive Maintenance 6, Maintenance Inventory and Purchasing 7. Maintenance Automation 8. Operations/Facilities Involvement 9, Maintenance Reporting 10. Predictive Maintenance 11. Reliability Engineering 12. Maintenance — General Practi 13. Financial Optimization 14. Asset Care Continuous Improvement 15. Maintenance Contracting 16. Document Management ‘Total26 Chapter 1 While these individual totals provide useful information, you may also want to plot your results in a spider diagram, using a product such as Mi- crosoit’s Excel, The results for the survey would then look like the diagram on the previous page. Using this survey, a modified version, or some similar survey is necessary for conducting an internal analysis. In turn, that analysis is an important ite to beginning any benchmarking project.